the finite element analysis of 3 stage helical gearbox that constitutes the driving mechanism of a double bascule movable bridge was performed. The triple reduction helical gearbox was made of ASTM A36 Steel. The triple reduction helical gearbox was a three stage gearbox transmitting 112.5 H.P. at 174 rpm with a reduction ratio of 71.05:1. The Differential gearbox was a single stage gearbox transmitting 150 H.P. at 870 rpm with reduction ratio of 5:1 The load calculation for helical, herringbone, and bevel gears were performed using the MATHCAD Software package. The reactions were used to apply loads to the finite element model of housing (casing). Geometric model of 3 stage helical gearbox was built using NX-8 and meshed using the ANSYS finite element program. Linear structural analysis was performed using a combination of shell and solid elements to determine the deflection and to estimate the stress distribution in the housing. Nonlinear analysis was later performed using shell, solid, and beam & gap elements to determine if the interface between the two halves of the housing separated and contributed to any undesirable misalignments of the shafts or bearings. In the triple reduction gearbox, the axial forces caused a maximum displacement 0.05588 cm. The location and magnitude of the displacements would not contribute to the undesirable misalignment of the shafts and bearings. The maximum von Misses stress in the triple reduction gearbox was 9000 psi. The minimum factor of safety in the triple reduction gearbox was four. The nonlinear analysis determined that separation did not occur on the interface between the two halves of the gearbox housings.

1. IJSRD - International Journal for Scientific Research & Development| Vol. 1, Issue 9, 2013 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 2027
Stress Analysis and Design Modification of 3-stage Helical Gear Box
Casing
Patel Mitesh S.
R.M.S. Polytechnic, Vadodara, Gujarat, India
Abstract—the finite element analysis of 3 stage helical
gearbox that constitutes the driving mechanism of a double
bascule movable bridge was performed. The triple reduction
helical gearbox was made of ASTM A36 Steel. The triple
reduction helical gearbox was a three stage gearbox
transmitting 112.5 H.P. at 174 rpm with a reduction ratio of
71.05:1. The Differential gearbox was a single stage
gearbox transmitting 150 H.P. at 870 rpm with reduction
ratio of 5:1
The load calculation for helical, herringbone, and
bevel gears were performed using the MATHCAD Software
package. The reactions were used to apply loads to the finite
element model of housing (casing). Geometric model of 3
stage helical gearbox was built using NX-8 and meshed
using the ANSYS finite element program. Linear structural
analysis was performed using a combination of shell and
solid elements to determine the deflection and to estimate
the stress distribution in the housing. Nonlinear analysis was
later performed using shell, solid, and beam & gap elements
to determine if the interface between the two halves of the
housing separated and contributed to any undesirable
misalignments of the shafts or bearings.
In the triple reduction gearbox, the axial forces
caused a maximum displacement 0.05588 cm. The location
and magnitude of the displacements would not contribute to
the undesirable misalignment of the shafts and bearings. The
maximum von Misses stress in the triple reduction gearbox
was 9000 psi. The minimum factor of safety in the triple
reduction gearbox was four. The nonlinear analysis
determined that separation did not occur on the interface
between the two halves of the gearbox housings.
I. INTRODUCTION
This thesis focuses on the force, deflection, and stress
analysis 3 stage helical gearbox housing designed and
manufactured by steward machine company, Birmingham,
Alabama. These gearboxes are designed for high torque and
low speed applications for operating movable bridges, heavy
hoisting machinery, or other lifting mechanisms. The helical
and herringbone-bevel combination gearbox housings
analyzed in this thesis form the driving mechanism of a
double bascule movable bridge.
II. MOVABLE BRIDGES
Movable bridges are generally constructed over waterways
where it is difficult to build a fixed bridge high enough for
water traffic to pass under it. The common types of movable
bridges are the lifting, bascule, and swing bridges. The
bascule bridge is similar to the ancient drawbridge both in
appearance and operation. It may be in one span or in two
halves meeting at the center. It consists of a rigid structure
Fig. 1: Single Leaf Bascule Bridge [2]
Mounted at the abutment of a horizontal shaft about which it
swings in a vertical arc. A single leaf bascule bridge is
shown in Fig.1. The need for large counterweights and the
presence of high stresses in the hoisting machinery limit the
span of bascule bridges. The largest constructed span of a
double-leaf bridge is 336 ft [1]. A double Bascule bridge has
two leafs on each side and a total of four leafs that open and
close when the bridge is opened and closed. An AC motor
drives the differential gearbox D of a double bascule bridge
shown in the block diagram of Figure 1.2. The AC motors
are typically rated for 15-150 h.p. at 870 rpm. The
differential gearbox D drives the triple reduction gearboxes
T on both sides, which in turn drive the main pinion P. The
main pinion drives the rack R attached to the leaf of the
bridge. The differential gearbox allows equal load
distribution between the two output shafts. It consists of
herringbone, helical, and bevel gears. The triple reduction
gearbox consists of helical gears. A photograph showing the
operating gearbox mechanism of a single leaf movable
bridge is shown in Fig. 2.
Fig. 2: Block Diagram of an operating Mechanism of a
Double Bascule Bridge

2. Stress Analysis and Design Modification of 3-stage Helical Gear Box Casing
(IJSRD/Vol. 1/Issue 9/2013/0086)
All rights reserved by www.ijsrd.com 2028
REFERENCES
[1] Design of Gearbox – nptel by Indian Institute of
technology, Madras
[2] Strength of Materials by R.S. Khurmi
[3] Strength of Materials by R.K. Rajput
[4] Yi Mei, FangpingWang, "Finite Element analysis on
Thermal Structures of Heavy Machinery Gearbox"
[5] Tushar. N. Khobrade, P. Pridarshni ”STATIC
ANALYSIS OF GEAR BOX CASING ”Aurangabad
[6] Practical Finite Element Analysis by Nitin S. Gokhale.
[7] Finite Element Modelling for Stress Analysis by Robert
D. Coo